Methods of forming dental positioning appliances

ABSTRACT

Methods of forming dental positioning appliances, such as removable mesh dental appliances. Methods may include forming one or more dies based on a digital three-dimensional model of one or more teeth. Methods may include applying a mesh material onto one or more dies having a three-dimensional shape corresponding to one or more teeth and shaping the mesh material via interaction with the one or more dies to conform to one or more surfaces of one or more teeth. The mesh material may be shaped to conform to an inside, an outside, and/or a biting surface of one or more teeth. The methods may include encapsulating the shaped mesh material into a polymer shell to form a dental positioning appliance.

CLAIM OF PRIORITY

This application is a divisional of U.S. patent application Ser. No.15/814,192, filed Nov. 15, 2017, now U.S. Patent Application PublicationNo. 2018/0071055, which is a continuation of U.S. patent applicationSer. No. 14/578,244, filed on Dec. 19, 2014, now U.S. Pat. No.9,820,829, which is a continuation of U.S. patent application Ser. No.13/431,783, filed on Mar. 27, 2012, now U.S. Pat. No. 8,944,812, whichis a continuation of U.S. patent application Ser. No. 12/247,559, filedOct. 8, 2008, now U.S. Pat. No. 8,152,518, the entire contents of whichare hereby incorporated by reference.

BACKGROUND

The present disclosure is related generally to the field oforthodontics. More particularly, the present disclosure is related to adental positioning appliance having one or more metallic portions.

Many orthodontic treatments involve repositioning misaligned teeth andchanging bite configurations for improved dental function and cosmeticappearance. Repositioning can be accomplished, for example, by applyingcontrolled forces to one or more teeth over a period of time.

Some orthodontic processes use removable positioning appliances forrealigning teeth. Such appliances may utilize a thin shell of materialhaving resilient properties, (an individual appliance is referred to asan “aligner”) whereby each appliance generally conforms to a patient'steeth but is slightly out of alignment with the initial toothconfiguration.

Placement of such an appliance over the teeth can provide controlledforces in specific locations to gradually move the teeth into a newconfiguration. Repetition of this process with successive appliancesthat provide progressive configurations eventually move the teeththrough a series of intermediate arrangements to a final desiredarrangement. An example of such a system is described in U.S. Pat. No.5,975,893.

Such systems typically utilize materials that provide light weightand/or transparent appliances in a set that can be used serially suchthat as the teeth move, a new appliance can be implemented to furthermove the teeth. Such features may be beneficial in many instances,however, in some instances, it may be desirable to provide movement withless appliances, thereby reducing modeling and manufacturing costs aswell as reducing the number of appliances the user has to utilize andkeep track of, among other benefits. Additionally, if the appliance isdesigned to treat a smaller number of teeth within a patient's mouth,then it may be difficult to create a sufficient anchoring force ormotive force with a plastic material used to form many such appliancesthat would be used to make the movements to the teeth that are desired.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a lower jaw of a subject together with an example ofa dental positioning adjustment appliance embodiment according to thepresent disclosure.

FIG. 1B illustrates a cut away view of the appliance of FIG. 1A takenalong line 1B-1B.

FIG. 2A illustrates a lower jaw of a subject together with an example ofseveral dental positioning adjustment appliance embodiments according tothe present disclosure.

FIG. 2B illustrates a cut away view of one of the appliance embodimentsof FIG. 2A taken along line 2B-2B.

FIG. 2C illustrates a cut away view of another appliance embodimenttaken along a similar line as FIGS. 1B and 2B.

FIG. 3 illustrates an embodiment of a mechanism that could be used toform one or more appliance embodiments of the present disclosure.

FIG. 4 illustrates a process for forming an appliance according to oneor more embodiments of the present disclosure.

FIG. 5 illustrates a general method for forming an appliance accordingto one or more embodiments of the present disclosure.

FIG. 6 illustrates a method for forming an appliance according to one ormore embodiments of the present disclosure.

DETAILED DESCRIPTION

According to the present disclosure, appliances and methods are providedfor utilizing metallic portions in dental positioning appliances. Insome embodiments, a removable dental positioning appliance has a shellwith one or more cavities shaped to receive and reposition one or moreteeth from a first orientation to a successive orientation and where atleast a portion of the shell is formed from a metallic material (e.g.,metallic mesh material). In various embodiments, the shell can be shapedto accommodate one tooth or multiple adjacent or nonadjacent teeth basedupon the number and position of the one or more cavities that form theone or more portions of the shell.

FIG. 1A illustrates a lower jaw of a subject together with an example ofa dental positioning adjustment appliance embodiment according to thepresent disclosure. In the embodiment of FIG. 1A, the appliance 100includes a mesh made out of a metallic material 110.

In various embodiments, the metallic material can be a planar sheet ofmaterial, strips of material, or one or more wires, among other materialconfigurations and can be in a mesh, solid, perforated, layered,adjacently oriented, or other type of configuration. In the embodimentof FIG. 1A, the appliance is formed by one or more wires arranged in anoverlapping pattern to form a mesh.

In some embodiments, a single wire can be woven to form the mesh. In theembodiment illustrated in FIG. 1A, multiple vertical wires 112 areprovided. In the embodiment illustrated in FIG. 1A, multiple horizontalwires 114 are also provided. In various embodiments, as shown in theembodiment of FIG. 1A, the wires can be laid over each other and/orwoven together.

As will be discussed in greater detail herein, the wires can beunfastened or can be fastened together in various manners. For example,the wires can be frictionally held together such as by weaving or tying,or held together by another material, such as solder, plastic, and/or anadhesive material among other suitable materials. In some embodiments,these materials can be coated onto or encapsulating around a portion of(e.g., such as the junctions 116 or other portions of wires 112 and 114of the embodiment of FIG. 1A) or an entire wire or the mesh as will bediscussed in more detail herein.

The methods of the present disclosure can employ any positioners,retainers, and/or other removable appliances for finishing andmaintaining teeth positions in connection with orthodontic treatment.The systems for use with embodiments of the present disclosure provide aplurality of such appliances can be intended to be worn by a patientsuccessively in order to achieve the gradual tooth repositioning asdescribed herein.

In such embodiments, such as that shown in FIG. 1 , an appliance 100can, for example, be fabricated from a shell having at least a portionformed from a metallic material. In various embodiments, the metallicmaterial can be utilized to provide a resilient functionality sufficientto move at least one tooth.

In the embodiment of FIG. 1A, the metallic portion is utilized to form acavity shaped to receive and resiliently reposition one or more teethfrom one teeth arrangement to a successive teeth arrangement. The shellmay be designed to fit over a number of, in many instances all teeth,present in the upper or lower jaw 101.

In some situations, certain individual or small sets of the teeth can berepositioned while others of the teeth can be used to provide a base oranchor region for holding the repositioning appliance in place as itapplies the resilient repositioning force against the tooth or teeth tobe repositioned. In some embodiments, the metallic portion of the shellcan be oriented to provide additional support with respect to holdingthe appliance in place. Such embodiments can aid in stabilizing one ormore teeth.

Such orientation can be beneficial, for example, where the tooth orteeth used as an anchor may have been recently moved and may not provideas much support as teeth that have not been moved. Such orientation canalso be beneficial, for example, where a larger anchoring force may beneeded than can typically be provided by the number of teeth being usedas the anchor. In such instances, the metallic portion can be placed ator near the tooth or teeth used for anchor to provide support and/orforce to provide the anchoring functionality.

In various embodiments, the metallic portion of the appliance can beoriented to provide the repositioning force whereby a plastic shellportion of the appliance provides a stabilizing anchoring support forthe device. This orientation enables the conformation of the shellportion to adapt to the anchoring teeth and depending on the metalproperties selected, a greater effective range for force generation onthe repositioning portion of the appliance.

FIG. 1B illustrates a cut away view of the appliance of FIG. 1A takenalong line 1B-1B. In this illustration, the mesh structure of theembodiment of FIG. 1A can be observed more closely.

In the embodiment of FIG. 1B, the appliance 100 includes a number ofwires forming a mesh pattern 110. The wires illustrated in FIG. 1Binclude a number of generally vertical wires 112 and a number ofgenerally horizontal wires 114.

In various embodiments, the wires may be in different orientations, suchas, but not limited to, non-horizontal and/or non-vertical, and/orirregular. Further, in some embodiments, the wires may be non-linear.For example, a wire may be bent in one direction (e.g., one axis withrespect to an axis of the elongation direction of the wire), as shownwith respect to wires 112 in FIG. 1B, or more than one direction (e.g.,in two axial directions with respect to the axis of elongation of thewire).

The wires may include alternating active and passive wires, in someembodiments. In other words, varying wire materials may be presentwithin the mesh.

Non-metallic wires may be incorporated into the mesh for additionalsupport or improved esthetics, among other benefits. For example, metalfibers may be alternated with composite fibers to create a hybrid mesh.

In the embodiment illustrated in FIG. 1B, the vertical wires 112 arelayered over the horizontal wires 114. As stated above, however, invarious embodiments, the wires (e.g., 112 and 114) may be woven togethersuch as in an alternating over-under type pattern.

In embodiments, such as that shown in FIG. 1B, the wires form a numberof junctions 116 where the wires cross each other. As discussed above,the wires can, in some embodiments, be fastened together at thesejunction points. The fastening can be accomplished, for example, by amechanical bracket type fastener, tied together, or by some type of bondbeing formed. Bonding mechanisms can include, for example, resins,adhesives, solder, polymers, and other materials that can be used toconnect two wires together.

FIG. 2A illustrates a lower jaw of a subject together with an example ofseveral dental positioning adjustment appliance embodiments according tothe present disclosure. In the embodiment of FIG. 2A, the appliance 200includes a number of metallic portions 220, 222, and 224. In someembodiments, these portions could each be a separate (or part of aseparate) dental appliance.

In the embodiment of FIG. 2A, the portions 220, 222, and 224 are part ofa one piece shell 200 that has other portions formed from an othermaterial than the metallic material of portions 220, 222, and 224. Inthe embodiment of FIG. 2A, the metallic material is a mesh material 210which can, for example, be formed by wires or strips of material, by asheet of material with holes punched therein, or in other manners. Theother material described above can be any suitable material for coatingand/or connecting to the one or more metallic portions 220, 222, and/or224.

The embodiment of FIG. 2A includes tooth structures 220 and 224 thatwhere each of the teeth is reinforced with metallic material 210 thatspans at least the buccal and mesial surfaces. Such embodiments can beuseful for a variety of purposes. For example, the mesh material can beused to further aid in anchoring a tooth.

The mesh material can be used to apply extra force to a particular toothand/or to extend the ability of the appliance to move the tooth.Depending upon the type of material used to form the mesh, the distanceof the movement of the tooth can be elongated, because the forceimparted by the metallic material may be over a greater distance thanother materials, such as some polymers and other materials.

In various embodiments, the length of time that the movement can takeplace can be elongated because the metallic material may not lose itsability to impart force as readily as some other materials, such as somepolymers and other materials. In some embodiments, the length of timethat movement of a tooth takes may be reduced because the metallicmaterial can impart either a greater force or more consistent force overa greater range of movement than some other materials, such as somepolymers.

In the embodiment of FIG. 2A, a portion includes a metallic material. Inthis embodiment, the portion 222 includes a metallic mesh material thatis provided on a surface (e.g., lingual) that is typically not visibleto a person looking at the patient's mouth and therefore, this may be adesirable embodiment for such situations. The use of a metallic portionon one or more selected surfaces, such as is shown in the portion 222 ofthe embodiment of FIG. 2A can also be used, for example, to impart aparticular force on the tooth (e.g., anchoring force, movement force,etc.). It should be noted that in some embodiments, the metallicmaterial can be placed between two teeth which may provide an anchoringforce or movement force to one or both of the teeth.

In some embodiments, as will be discussed in more detail herein,portions of or the entire appliance can be coated with a secondmaterial. This second material can be used to form the other portions(i.e., the portions other than 220, 222, and 224) of the dentalappliance described above, in some embodiments.

In various embodiments, the second material could be a coating over,under, or encapsulating the portions 220, 222, and 224. Materials thatcan be used can include solders, epoxies, glues, polymers, oxides, andother suitable coating materials. In various embodiments, the materialsmay be bio-compatible materials.

Coatings can provide, for example, a more palatable texture, interactionwith tooth surfaces, and/or taste than the metallic material, amongother benefits. Another benefit may be that the coating can be used tohold one or more of the wires (e.g., wires 212 and 214 in the embodimentof FIG. 2A), forming the mesh, in place. Another benefit can be that asecond material may be more pleasing to the eye than the metallicmaterial and therefore, may be more desirable to be used in viewableareas of the oral environment, such as the buccal, occlusal, and/ormesial surfaces of a tooth or teeth, among other surfaces.

FIG. 2B illustrates a cut away view of one of the appliance embodimentsof FIG. 2A taken along line 2B-2B. In the embodiment of FIG. 2B, theappliance includes a metallic mesh material 210 having a second material(e.g., a coating) 226 on the outside of the mesh portion 210.

In various embodiments, a second material can (i.e., in addition to themetallic material), for example, be placed at one or more junctions ofthe wires (e.g., junctions 116 of FIG. 1B), can be applied over (e.g.,as illustrated in FIG. 2B at 226) or under portions or all of a wire orthe mesh, or can be applied to encapsulate portions or all of a wire orthe mesh. In some embodiments, this second material can be or includeone or more agents that can be dispensed into the oral environment. Itmay be appreciated that any suitable agents, such as fluoride materials,antibiotics and/or antimicrobials and/or other chemicals, drugs,metallic ions, or medications, such as vitamins, bleaching materials,and/or breath fresheners, may be delivered to the oral environment inthis manner.

In such embodiments, the second material may be oriented on theappliance such that it can be positioned proximate to an area needingsuch an agent. Accordingly, the second material can be selectivelyapplied to particular portions of the appliance in such embodiments.

In various embodiments, the appliance may include one or more metallicportions and one or more non-metallic portions where at least one of thenon-metallic portions forms part of the appliance body (e.g., where theappliance is part metallic and part polymeric) and at least one of thenon-metallic portions is a coating formed over at least a portion of thebody of the appliance (e.g., where an agent is applied over a portion ofthe metallic and/or polymeric portions of the appliance). In someembodiments, an agent can be impregnated into a material (e.g., apolymeric material) and can be released out of the material byinteraction with the oral environment.

As illustrated in the embodiment of FIG. 2B, a coating can be appliedover the metallic material. In some embodiments, a second material canbe applied under the metallic material. Such embodiments can bebeneficial, for example, where the metallic material may interfere withfilling material, where tooth surfaces may be sensitive to metallicmaterials, and/or where it may be desirable to provide a softer and/ormore uniform interface surface for contacting the surfaces of one ormore teeth, among other benefits.

FIG. 2C illustrates a cut away view of another appliance embodimenttaken along a similar line as FIGS. 1B and 2B. In the embodiment of FIG.2C, the metallic portion 210 is shown as being encapsulated within thesecond material 226.

Such embodiments can have one or more of the above recited benefits. Itshould be noted that such an illustration may be representative of anentire appliance that is fabricated from a metallic material andencapsulated within a second material or where a portion of an applianceis fabricated with a metallic material and where that portion isencapsulated.

For example, in some embodiments, the appliance may be formed mostlyfrom a polymeric material and where a metallic material is encapsulatedin a portion. Such embodiments may aid in reinforcing or providingadditional force to a particular area.

The metallic material, such as a metallic mesh material can be formed bymetal injection molding, by casting (which may include heat-treatmentpost-casting), by stamping the appliance using a stamp, by pressingand/or heat treating with a mold, or by bending individual metallicportions (e.g., wires) and/or soldering the individual wire componentstogether, among other techniques. In some embodiments, the metallicmaterial may be arch-preformed.

In some embodiments, the metallic material may be friction shapedthrough a pressing or other type of process wherein the material isshaped through a friction involving process. In various embodiments, themetallic material may be ultrasonically heated to maintain or obtain adesired shape.

In some embodiments, once the shape is formed, the metallic material canbe coated with a second material. For example, in some embodiments, thecoating can be sprayed or dip coated onto the metallic material. Invarious embodiments, the appliance can be cut (e.g., by a mechanicalcutting tool or laser cutting tool) to trim the edges.

In some embodiments, the computing device executable instructions forthe cutting tool may be programmed to cut at mesh junctions to avoidsharp points in the final product. In some embodiments, the appliancemay be dipped in a coating to cover any sharp edges, among other sharpedge solutions.

There are several processes that can be used to form the appliance orportion thereof having metallic material. FIGS. 3 and 4 illustrate twosuch ways and discussion is provided about some other processes that maybe utilized.

FIG. 3 illustrates an embodiment of a mechanism that could be used toform one or more appliance embodiments of the present disclosure. In theembodiment of FIG. 3 , a portion of a mechanism 303 is illustrated thatcan be used to form a portion of the shape of an appliance such as thoseillustrated in FIGS. 1A-2C.

FIG. 3 shows a cross-sectional view of the forming of an appliance froma metal sheet of material 330. It will be understood that this sheet ofmaterial could be a sheet of mesh material or other type of metallic orpartially metallic material.

In a process such as that illustrated in FIG. 3 , an appliance havingmetallic material can be pressed over a mold using a positive or, insome cases, a negative shape in a desired configuration. In someembodiments, metallic material can be sandwiched into a multi-pieceforming mechanism (e.g., a number of dies), to press and/or hold themetallic material in a desired shape.

In the embodiment of FIG. 3 , the forming mechanism 303 includes severalportions, namely portions 332, 334, 336, and 338. These at least some ofthese portions move toward one another to bend the sheet of material330.

In some embodiments, changes in temperature of the environment aroundthe mechanism 303, of the portions 332, 334, 336, and/or 338 and/or thematerial 330 can be used to create the desired shape and/or forceproperties of the appliance or portion being formed. In variousembodiments, some portion of the forming mechanism 303 or the entiremechanism can be formed from a metallic or ceramic material.

Where a shape memory type material is used as material 330, then, achange in temperature or stress can be applied to the material 330 toproduce the desired shape and/or force characteristics of the applianceor portion being formed. For instance, in some embodiments, the metallicmaterial can be a shape memory alloy formed at least in part fromnickel, titanium, copper, aluminum, and/or zinc, among other materials.

In such embodiments and as stated above, the metallic material may becoated for esthetics and/or hygiene among other considerations. In suchembodiments, the amount of movement built in can, for example, be basedon the amount of distortion that can be tolerated to still ensureappliance fit.

FIG. 4 illustrates a process for forming an appliance according to oneor more embodiments of the present disclosure. In the embodiment of FIG.4 , an appliance or portion thereof can be formed over a positive model444 of a desired shape, using a carrier material 440 to enable formationof the metallic material (e.g., metallic mesh material) 442 around thedesired shape 444. The metallic material 442 can then be set, forexample, with high heat. The carrier material 440 can then be removed byany suitable manner.

One suitable manner, for example, may be that the carrier material 440is a dissolvable material, which can be removed by dissolving with asolvent such as water, organic solvent, or other solvent types. In someembodiments, the carrier 440 may be a wax which can be melted or burnedoff.

Another process for creating appliance embodiments or portions thereofmay be to bend the individual ribs in a mesh material and then toassemble the individual ribs with connecting wire and solder orotherwise attach the framework together.

Various embodiments of the present disclosure can enable a longer rangeof movement to be built into an appliance without increasing the amountof force placed on the teeth. In other words, through use of shapememory alloy materials, for example, it may be possible for an applianceto provide the movement of 5 to 10 polymeric appliances withoutincreasing patient discomfort and/or negative biological effects of highforce on the one or more teeth.

As a result of such embodiments, fewer appliances may have to be built,thereby reducing materials costs and/or visits to the treatmentprofessional, among other benefits. Another possible benefit is becausethe material is metallic it may be easier to disinfect an appliance, insome instances.

FIG. 5 illustrates a method of forming a removable dental positioningappliance according to one or more embodiments of the presentdisclosure. In the embodiment of FIG. 5 , the method includes formingone or more dies based upon a machine readable three dimensional modelof at least one physical tooth to be moved, at block 550. A metallicmaterial can be applied onto at least one of the dies, as provided inblock 552.

The metallic material can be shaped via interaction with each of thedies to form a dental positioning appliance, at block 554. In thismanner, the metallic appliance can be shaped to fit the intended user.

In various embodiments, one or more methods can include applying ametallic material that is a metallic mesh material. Applying themetallic material can include applying at least one wire.

Shaping the metallic material can include pressing the metallic materialbetween at least two of the dies. In some embodiments, shaping themetallic material can include bending the metallic material into contactwith at least one of the dies.

In some embodiments, a method can include applying a coating to at leasta portion of the appliance. Method embodiments can also include heatingthe metallic material to change the material into a shape memorymaterial.

In various embodiments, a method can include trimming one or more edgesof the appliance. Methods can also include polishing one or moreportions of the appliance. In some such embodiments, a method caninclude forming the shell into a dental positioning appliance orincorporating the shell into a dental positioning appliance.

In some embodiments, the appliance can be a mouth guard that protectsteeth, but may or may not do any positioning of teeth. In suchembodiments, the mouth guard can be coated with a thicker coating or thecoating material can provide more shock absorption. Any suitable mouthguard features, design, or materials can be utilized with embodiments ofthe present disclosure.

FIG. 6 illustrates a method for forming an appliance according to one ormore embodiments of the present disclosure. Although discussed withrespect to a mesh material, FIG. 6 should be interpreted to be suitablefor metallic materials in generally and not limited to mesh materials.

In the embodiment of FIG. 6 , the method includes creating one or moremesh shapes at block 660. The mesh shapes can be final or intermediatetooth configurations and can, for example, be created with a computingdevice aided drafting (CAD) program in two or three dimensions. In someembodiments, the mesh shapes may conform exactly to the shape of theteeth in the entire arch or may conform exactly only to a portion of theteeth in the arch, among other configurations.

In some embodiments, and as illustrated at block 662, the method of FIG.6 includes digitally sectioning the mesh shapes in a 3-D environment.The digital sectioning of the mesh shapes can be used to createdifferent dies for different metallic portions of the appliance ifsuitable for manufacturing.

Block 664 includes creating a computerized negative or inverse receivingdie geometry of shapes. In the embodiment of FIG. 6 , the die geometryis a computerized master 3-D type of die that can be used for formingmultiple appliance dies.

At block 666, the master die and individual section pieces (e.g.,forming mechanism portions) are printed and heat resistant forms arecreated. Forming one or more dies can include forming at least one diefrom a metallic or ceramic material.

In the embodiment illustrated in FIG. 6 , raw metal alloy mesh ispositioned against the master die at block 668. The sections are thenassembled to sandwich the material into a selected shape at block 670.The metallic material can then be heat treated, if desired to create ashape memory alloy as discussed at block 672.

At block 674, the sections are removed and the formed metallic materialis separated from the die. In such embodiments, the material can then betrimmed and/or polished, if desired, as indicated at block 676. In someembodiments, as illustrated at block 678, a coating can be added.

Although specific embodiments have been illustrated and describedherein, those of ordinary skill in the art will appreciate that anyarrangement calculated to achieve the same techniques can be substitutedfor the specific embodiments shown. This disclosure is intended to coverany and all adaptations or variations of various embodiments of thedisclosure.

It is to be understood that the use of the terms “a”, “an”, “one ormore”, “a number of”, or “at least one” are all to be interpreted asmeaning one or more of an item is present. Additionally, it is to beunderstood that the above description has been made in an illustrativefashion, and not a restrictive one. Combination of the aboveembodiments, and other embodiments not specifically described hereinwill be apparent to those of skill in the art upon reviewing the abovedescription.

The scope of the various embodiments of the disclosure includes anyother applications in which the above structures and methods are used.Therefore, the scope of various embodiments of the disclosure should bedetermined with reference to the appended claims, along with the fullrange of equivalents to which such claims are entitled.

In the foregoing Detailed Description, various features are groupedtogether in a single embodiment for the purpose of streamlining thedisclosure. This method of disclosure is not to be interpreted asreflecting an intention that the embodiments of the disclosure requiremore features than are expressly recited in each claim.

Rather, as the following claims reflect, inventive subject matter liesin less than all features of a single disclosed embodiment. Thus, thefollowing claims are hereby incorporated into the Detailed Description,with each claim standing on its own as a separate embodiment.

What is claimed is:
 1. A method of forming a removable mesh dentalpositioning appliance, the method comprising: forming one or more diesbased upon a machine-readable three-dimensional model of at least onephysical tooth; applying a material onto at least one of the dies,wherein the material includes one or more portions oriented in a firstdirection and one or more portions oriented in a second direction,wherein the one or more portions oriented in the first direction and theone or more portions oriented in the second direction cross one another;and shaping the material via interaction with each of the dies to form amesh dental positioning appliance conforming to an inside, outside, andbiting surface of the at least one physical tooth.
 2. The method ofclaim 1, wherein applying the material includes applying a coating to atleast a portion of the appliance.
 3. The method of claim 2, wherein thecoating is a polymeric material.
 4. The method of claim 1, whereinapplying the material includes applying at least one wire.
 5. The methodof claim 1, wherein shaping the material includes pressing the materialbetween at least two of the dies.
 6. The method of claim 1, whereinforming one or more dies includes forming at least one die from at leastone material selected from the group including: metallic and ceramicmaterials.
 7. The method of claim 1, wherein the method includes heatingthe material to change the material into a shape memory material.
 8. Themethod of claim 1, wherein shaping the material includes bending thematerial into contact with at least one of the dies.
 9. The method ofclaim 1, wherein the method includes incorporating a shell into thedental positioning appliance.
 10. The method of claim 1, wherein thematerial is applied onto a portion of the at least one of the diescorresponding one or more first cavities of the mesh dental positioningappliance, the one or more first cavities shaped to conform to andresiliently apply a repositioning force on one or more teeth forrepositioning.
 11. The method of claim 10, wherein one or more secondcavities of the mesh dental positioning appliance are shaped to fit overone or more anchoring teeth.
 12. A method of forming a removable dentalpositioning appliance, the method comprising: forming one or more diesbased on a digital three-dimensional model of the one or more teeth;applying a mesh material onto the one or more dies; and shaping the meshmaterial via interaction with the one or more dies to form the removabledental positioning appliance conforming to one or more of an inside, anoutside, and a biting surface of the one or more teeth.
 13. The methodof claim 12, wherein the mesh material has a carrier material attachedthereto when applying the mesh material onto the one or more dies. 14.The method of claim 12, wherein forming the one or more dies includesforming multiple dies that cooperate to shape the mesh material inaccordance with the one or more teeth.
 15. The method of claim 12,further comprising encapsulating the shaped mesh material into a polymershell.
 16. The method of claim 15, wherein the mesh material is formedas a one or more first cavities of the removable dental positioningappliance, and wherein one or more second cavities of the removabledental positioning appliance do not include the mesh material.
 17. Themethod of claim 12, wherein the mesh material is made of a shape memorymaterial.
 18. A method of forming a removable dental positioningappliance, the method comprising: applying a mesh material onto one ormore dies having a three-dimensional shape corresponding to one or moreteeth; shaping the mesh material via interaction with the one or moredies to conform to one or more of an inside, an outside, and a bitingsurface of the one or more teeth; and encapsulating the shaped meshmaterial into a polymer shell to form the removable dental positioningappliance.
 19. The method of claim 18, further comprising forming one ormore dies based on a digital three-dimensional model of the one or moreteeth.
 20. The method of claim 19, wherein forming the one or more diesincludes forming multiple dies that cooperate to shape the mesh materialin accordance with the one or more teeth.